Document K6K8gNrqgmXJJp7VgBLkR7EK0
INC. ESCAMilA PLANT
INTEROFFICE MEMORANDUM
R. L. Duggan
From: L. W. Allen/R. H. Sroufe
Re: VCL Emission Test Escambia PVC Plant
Date: Copies:
19 October 1978
The VCL emission test was completed on the PVC Plant, and the plant is in compliance. The test was conducted on 17 October as scheduled. Mr. Bill Thomas, Florida Department of Environmental Regulation (Bureau of Air Quality Management) witnessed the test, and Dr. James Wu, EPA, who arrived after testing, reviewed all of the procedures and results. Equipment operating data was taken and is attached. Analytical data for all analyses are also attached. The attached report contains the following.
Description of equipment. Conditions during tests. Production calculations, Emission test procedures.
Emission test results.
LWA-RHS: fls Attachments
L, W. Allen/R. H. Sroufe
AP00042823
ESCAMBIA BSlLA4UNVT
^
I. PVC THERMAL. OXIDIZER
The purpose of the thermal oxidizer Lb to reduce the vinyl chloride monomer discharged to the air below 10 ppm concentration (measured by Method 106).
Process gases are purged from the vinyl chloride recovery system. The system consists of compressors and heat exchangers (cooling water, refrigerated water, and freon).
On October 17, 1978, the entire heat exchanger system was shut down. This was done to provide an adequate vinyl chloride feed for the thermal oxidizer. Shutting down the heat exchanger system is not standard procedure. This increased the vinyl chloride in the feed composition above normal operating levels,
Thermal oxidizer feed samples and flow measurements were taken hourly. The vinyl chloride concentration in the feed increased from 42. 2% to 60. 8%. Mass flow rate of vinyl chloride Increased from 21.76 lbs. peT hour to 34.63 lbs. per hour.
Method for Calculation of Vinyl Chloride Feed Flow to the Thermal Oxidizer - Example:
Basis. A Gas Chromatographic Analysis was done on feed samples.
CO CO 2 CH3C1 Vinyl Chloride
7. 1%
44.9%
1.8%
3.8%
.2%
42.2%
Specific Gravity of Gas 1.5; Feed Tank Pressure 30 pslg; Ambient Temperature 52F.
Principles and Practice of Flow Meter Engineering, by L, K. Spink 9th Edition, Nov. 1975.
QN = Cg, Ftf Fg Fpv Fa VhaPf
Cg, = Orifice Size = .250" = (17.84) pg 187
Ftf = Fg = Fpv * Fa -
Flowing Temperature, pg. 454 (1.008) Specific Gravity, pg. 455 (.8165) Compressibility Factor, pg. 464 (1.026) Temp. Correction on Orifice, pg. 156 (1.000)
AP00042824
ESCAMBIA PLANT
page 2
I. PVC THERMAL OXIDIZER (cont'd)
Qn = (17,84) (1.008) (.8165) (1.026) (1.000) ( -y(20)(44. 7) ) = 450 SCFH pa La
PPH SCFH x S. G. = 450 x 1,5 = 51.52 #/hr. of waste gas
13.1
13.1
Vinyl Chloride Flow = 51.52 #/hr. x .422 = 21.74 #/Hr.
Thermal Oxidizer Emission Tests
The thermal oxidizer was sampled and analyzed on 17 October according to EPA Method 106. The testing began as scheduled at 7:30 a.m. Three samples were taken.
During the tests the stack air flow was constant at 202 5CFM according to a pitot manometer. The sample air flow was constant at 1.42 liters per minute to provide an 85 liter sample each hour. The rigid leakproof container and Tedlar sample bags were leak checked prior to and after testing. The equipment was found to be sealed in accordance with Method 106.
The gas samples were taken to the lab Immediately after sampling. The samples were protected from sunlight and analyzed within 4 hours. Method 105 was used on all analyses. The test results are detailed below:
Thermal Oxidizer Emissions Test
Test 1
Test 2
Test 3
Average
Sample Time Sample Volume % Oxygen PPM, VC1
1 hour 85 liters 7. 1 None Detected
1 hour
85 liters
6.9
None Detected
1 hour 85 liters 5.5 1. 52
<1.5 ppm
The analytical results and operating data of each test run are attached in the Appendix.
AP000
-------\
ESCAMBIA PLANT
II. NORTH LINE STRIPPER COLUMN-
The north line stripper is designed to reduce the vinyl chloride below 400 ppm. concentration in the slurry from the north line reactors, (measured by Method 107). This is accomplished by 40 pound steam flowing up through stripping column and heating the slurry to flash off the vinyl chloride. The vinyl chloride gas Ls then cooled in the overhead condenser. Vent from the condenser is sent to the recovery system. The liquid is sent to the waste water stripping column.
During the test period the stripper operated at design rates which are greater than normal permitted rates.
Sample Calculation
Basis: Operating Conditions During EPA Testing
Period - 10/17/78
lb. PYC = Slurry Feed (gpm) x 8.33 lb. x 1. 11 slurry specific gravity x
hr.
gal.
0.32 lb. PVC x 60 min.
lb. slurry
hr.
lb. PVC = 112 gpm x 8.33 #/gal. x 1. 11 x .32 #/PVC x 60 min/hr.
hr.
# slurry
r= 19; 883.24 #/hr.,rate
This translates to an equivalent annual production rate of 174. 2 MM pounds of PVC. The north line rated production capacity is 120 MM pounds of PVC per year.
AP00042826
erffo'Phjx&ietl <*W CAemoa&
ESCAMBIAA PMLl AANkiTV
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II, NORTH LINE STRIPPER COLUMN
North Line Stripper Emission Test
The north line stripper was sampled and analyzed on 17 October according to EPA Method 107, The testing began as scheduled. Three samples were taken.
Prior to sampling, the sample line was completely purged. 60 ml. sample bottles with waxed lined screw tops were used. After sampling the bottles were taken to the lab for immediate analysis. Operating data was collected during the tests and is attached in the appendix. The test results are detailed below.
North Line Stripper Column Emissions Teat
Sample time Sample volume ppm VCL
Test 1
Test 2
Test 3
Average
7:30 a.m. 60 ml 47.9
9:10 a.m. 60 ml 160.2
10:45 a.m. 60 ml 161.2
122.9 ppm
The analytical results of each test are attached in the appendix.
AP00042827
At
-------X
ESCAMBIA PLANT
<N
III. SOUTH LINE STRIPPER COLUMN
The south line stripper Is designed to reduce the vinyl chloride concentration in the Blurry from the south line reactors below 400 ppm. (measured by Method 107). This is accomplished by 40 pound steam flowing up through the stripping column and heating the slurry to flash off the vinyl chloride. The vinyl chloride gas is then cooled in the overhead condenser. Vent from the condenser is sent to the recovery system. The liquid is sent to the waste water stripping column.
During the test period the stripper operated at design rate which is greater than normal, permitted rates.
Sample Calculation
Basis:
Operating Conditions During EPA Testing Period 10/17/78
Lb. PVC hr.
= Slurry Feed (gpm) x 8. 33 lb. x 1. 11 Slurry Specific Gravity x
gl*
0.32 lb. PVC x 60 min.
lb. slurry
hr.
Lb. PVC hr.
41 gpm x 8. 33 #/gal. x 1. 11 x 32 #PVC x 60 min.
1# slurry
hr.
= 7.278. 7 #/hr.
This translates to an annual production rate of 63.8 MM pounds of PVC. The south line production capacity is 30 MM pounds of PVC per year.
South Line Stripper Emission Test
The south line stripper was sampled and analyzed on 17 October according to EPA Method 107. The test began as scheduled at 7:30 a.m. Three samples were taken.
Prior to sampling, the sample line was completely purged. 60 ml sample bottles with waxed lined screw tops were used, After sampling, the bottles were taken to the lab for immediate analysis. Operating data was collected during the tests and is attached in the appendix. The test results are detailed below:
AP00042828
III.
South Lina Stripper Column (continued)
South Line Stripper Ernie a ions Test
Test 1
Test 2
Test 3
Average
Sample Time Sample Volume
PPM, VC1
9:25 a.m, 60 ml
21.39
11. 50 a. m. 60 ml 17.55
12.40 p. m. 60 ml 17.70
18.86 ppm
The analytical results of each test are attached in the Appendix.
AP00042829
ESCAMBIA PLANT
IV.
WASTE WATER STRIPPING COLUMN
The stripping column is designed to strLp vinyL monomer from water streams that contain more than 10 ppm vinyl chloride. Forty pound steam is fed into the column to flash the vinyl chloride out of the water.
During the test period the stripper operated at design rate which is greater than normal, permitted production rates.
Sample Calculation
Basis: Operating Conditions During EPA Testing Period - 10/17/78
Feed (lb. ) = Flow in Gal, x 60 min.
hr.
min.
hr.
x 8.33 lb. =20 gal, x 60 min.
hr.
min.
hr.
x 8.33 lb;_ = hr.
9,996 lb. hr.
Under normal plant operating conditions the column feed is 5, 998 lbs. hr.
WASTEWATER STRIPPER EMISSION TEST
The wastewater stripper was sampled and analyzed on 17 October according to EPA Method 107. The test began as scheduled at 7:30 a.m. Three samples were taken.
The stripper was sampled using 50 ml Hypo-vials sealed with teflon faced Guf-Bond discs. The sample vials were capped with aluminum foil without the discs and muffled at 400C for one hour prior to testing. The sample line was
purged and the vials were filled bubble free. The vials were sealed and taken to the lab for immediate analysis. The samples were refrigerated until analyzed.
Operating data was collected during the tests and is attached in the Appendix. The test results are detailed below:
Waste Water Stripper Emissions Test
Test 1
Test 2
Test 3
Average
Sample Time Sample Volume PPM, VC1
7.35 a. m. 50 ml 4. 67
9:15 a. m. 50 ml 5.37
10:40 a. m. 50 ml 11.99
7. 34 ppm
V. EQUIPMENT AND METHOD USED TO ELIMINATE REACTOR . opening LOSSES
Reactors are not being opened on a routine basis. Spray rinse timers have been installed on reactor sight glasses to improve visibility. This improved visibility eliminates the need for opening the reactors when coupled with the established chemical cleaning system.
A fill water system exists to fill the reactors completely (100%) with water before chemical cleaning. The vinyl chloride is purged from the reactors to the recovery system. This effectively eliminates the presence of vinyl chloride during chemical cleaning.
REACTOR OPENINGS
The emissions from reactor openings are essentially zero. The reactors are completely water filled and evacuated prior to openings. Therefore, emission testing is not required.
EPA observer. Dr. James Wu, accepted the system of abatement as a procedure. No emissions tests were required.
10/19/78
AP00042831
APPENDIX
I. Analytical Data Analytical Log Sheet - Test Results - Method 107 GC Strip Chart Method 107 Integrator Tape Method 106 GC Strip Chart Thermal Oxidizer Feed Analysis
II. Equipment Operating Data m North Line Stripper South Line Stripper Wastewater Stripper Thermal Oxidizer
AP00042832
ANALYTICAL DATA
AP00042833
ANALYTICAL LOG SHEET TEST RESULTS
AP00042834
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AP00042836
METHOD 107
INTEGRATOR TAPE
Column 2 6' x 1/8 SS packed w 0.2% Carbowax 1500 on Carbopack C 800/100 mesh
Carrier flow 20 we/min.
Chart speed 5 mm/min.
Stds.
4190 ppm 1999 ppm
514 ppm
55 ppm
AP00042837
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THERMAL OXIDIZER FEED ANALYSIS
AP00042853
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AP00042854
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